AKRAPOVIC RACING & EVOLUTION EXHAUST SYSTEM for the HONDA CBR 600 RR (2003)

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1 Installation instructions: *350019* AKRAPOVIC RACING & EVOLUTION EXHAUST SYSTEM for the HONDA CBR 600 RR (2003) Congratulations on purchasing an Akrapovic exhaust system. Please read these installation instructions carefully. If you have any trouble installing the system please contact your authorized dealer! IMPORTANT INFORMATION Exclusion of Certain Liability 1. The manufacturer, importer or dealer shall not be liable for any incidental damage including personal injury or any other damages caused by improper installation or operation of the Akrapovic exhaust system. When installing the Akrapovic exhaust system be careful that the exhaust system does not touch other parts sensitive to high temperature. 2. Akrapovic makes no representation or warranties with regard to damage caused by the improper installation, use and maintenance of the Akrapovic exhaust system. The warranty is limited to defects recognized by our technical department and to normal use, and excludes items subject to normal wear (gaskets and damping wool). The guarantee is void in case of accident, modification, improper or competition use. 3. Do not attempt to install the Akrapovic exhaust system on a motorcycle for which it was not made or tested by Akrapovic. 4. When the exhaust system gets very hot during operation, be careful not to burn yourself on the exhaust system or parts which are in direct contact with it, even when the motor is not running. Also protect other people, especially children, from the injuries mentioned above. 5. In some cases Akrapovic exhaust system kits contain chemical products (ceramic anti-seizing grease, bolt sealant). Handle with care, do not inhale or swallow. Avoid excessive contact with skin, eyes or mucous membranes. Keep out of reach of children. 6. Technical specifications of Akrapovic exhaust systems and related products subject to change without notice. Trademarks Akrapovic website Copyright Symbols The Akrapovic Exhaust System Technology logo is a registered trademark of Akrapovic d.. Information about Akrapovic exhaust systems and related products is available on the Akrapovic website at: No part of the Akrapovic exhaust system or its documentation may be reproduced or distributed in any form or by any means without the prior written authorization of the Akrapovic company. Akrapovic d.. All rights reserved. The following symbols are used throughout these installation instructions:! CAUTION OR WARNING INSTALLATION TIP NAV-017 1

2 INSTALLATION INSTRUCTIONS BEFORE INSTALLING CHECK THE EXHAUST SYSTEM SCHEMATIC!!!! IN CASE THAT SOME ITEMS IN THE AKRAPOVIC EXHAUST SYSTEM PACKAGE ARE MISSING PLEASE CONTACT YOUR AUTHORIZED DEALER. KEEP THE SCHEMATIC FOR FUTURE REFERENCE. IT IS ESSENTIAL TO READ THESE INSTALLATION INSTRUCTIONS CAREFULLY IN ORDER TO ENSURE PROPER INSTALLATION AND OPERATION OF THE AKRAPOVIC EXHAUST SYSTEM. THE EXHAUST SYSTEM CAN BE EXTREMELY HOT. LET THE MOTORCYCLE COOL DOWN BEFORE BEGINNING INSTALLATION. WE ADVISE YOU TO LEAVE INSTALLATION TO A QUALIFIED SERVICEMAN. IMPROPER INSTALLATION MAY RESULT IN A SHORTER LIFETIME OF THE EXHAUST SYSTEM AND/OR DAMAGE TO THE MOTORCYCLE. REMOVAL OF STOCK EXHAUST SYSTEM 1. put the motorcycle on a side stand, we recommend a racing stand 2. remove the rider s seat (bolts under the seat on both sides) and passenger s seat (Figure 1) 3. remove the fastback (6 bolts), lift the fastback from the left side viewed from the rear (Figure 2) be careful not to remove paint from the tank; disconnect the electrical leads for the rear light, turn signal lamps and license plate light from the connector (Figure 3) 4. remove the license plate holder and turn signal lamps (Figure 4) 5. remove the plastic leg protector which is above the heat shield right side of the motorcycle (viewed from the rear) and the rider s footrest bracket together with the cylinder for the rear brakes do not disconnect the brake fluid tube! (Figure 5 & 6) 6. unscrew the bolt from the metal clamp at the link pipe collector connection (Figure 7) 7. unscrew the bolt from the muffler bracket in the rear under the seat and not the bolt for the subframe (Figure 8 & 9) 8. hold the muffler from underneath with your left hand and remove the bolt from the muffler bracket i.e. the link pipe near the right-side passenger footrest (viewed from the rear) (Figure 10) 9. remove the link pipe from the muffler 10. remove the entire lower cowling (Figure 11) 11. remove the left side and right side middle cowling (Figure 12) 12. unscrew and remove both bolts (front (Figure 13) and rear (Figure 14)) from the water cooler bracket, so the cooler can be moved 13. unscrew the nuts on the header tube flanges 14. pull the header tubes out of the exhaust channels (Figure 15) (they remain attached to the collector bracket together with the collector at the rear) and unscrew the bolt on the collector bracket (Figure 16) 15. remove the stock header assembly (Figure 17) 16. leave the stock gasket in the slot in the exhaust channel INSTALLATION OF THE AKRAPOVIC RACING OR EVOLUTION EXHAUST SYSTEM installing the header tubes: 1. check the position of the cooler, being careful of the cooling fins 2. position the flanges together with the sleeves and springs (Figure 18) make sure the springs are correctly oriented for attachment to the eyelet for each header tube (Figure 19) 3. tighten the nuts on the flanges 4. tighten the rear bolt on the water cooler bracket (Figure 20) 5. position the header tubes in pairs (both collectors are paired with the header tubes in the Akrapovic kit) (Figure 21) 6. stretch the springs and move the header tubes gently in order to seat them 7. tighten the front bolt on the water cooler bracket (Figure 22) 8. make sure the header tubes and the collectors are not touching the engine, water cooler etc. (Figure 23) 9. remove the rubber and metal sleeves from the stock collector bracket (on both sides) (Figure 24) installing the independent link pipe: 1. check the orientation of the link pipe 2. slide the link pipe (inlet side) into the collector (Figure 25) 3. position the springs 4. loosely tighten the bolt on the link pipe bracket onto the frame of the motorcycle near the passenger footrest (Figure 26) 5. make sure the link pipe is not touching the frame or any other parts 6. position the bracket for the rider s footrest and the rear brake cylinder (Figure 27) 7. position the plastic guard near the rider s right footrest (Figure 28) installing the muffler: 1. orient the muffler correctly and slip it onto the outlet side of the link pipe 2. stretch the springs (Figure 29) 3. correctly position the carbon-fiber clamp and slide it onto the muffler. WARNING: open the clamp to slightly wider than the diameter of the outer sleeve of the muffler do not scrape it along the muffler outer sleeve! (Figure 30). Bear in mind the right offset of the carbon-fiber clamp viewed from the rear (Figure 31) 4. tighten the carbon-fiber clamp onto the stock bracket on the frame below the seat use the stock bolts or the replacements from the Akrapovic kit, if supplied (Figure 32) NAV-017 2

3 5. make sure that it is not touching any other parts of the motorcycle 6. correct position of the installed Akrapovic RACING or EVOLUTION system (Figure 33) final installation: 1. tighten the bolts on all of the brackets and clamps to which the exhaust system and the other dismounted parts of the motorcycle are attached 2. clean grease spots: a. muffler titanium outer sleeve: use a soft cloth sprayed with a multi-purpose spray lubricant (WD-40 or equivalent) b. muffler carbon-fiber outer sleeve: use a soft dry cloth c. stainless steel link pipe: use a soft cloth sprayed with a contact cleaner, then wipe with a soft dry cloth d. titanium link pipe: use a soft cloth sprayed with a multi-purpose spray lubricant (WD-40 or equivalent) e. evolution model exhaust (titanium header tubes): use a soft cloth sprayed with a z multi-purpose spray lubricant (WD-40 or equivalent) f. racing model exhaust (stainless steel header tubes): use a soft cloth sprayed with a contact cleaner, then wipe with a soft dry cloth Cleaning will prevent spots from burning onto the surface. Do not use aggressive chemical cleaners, because they can damage the sticker. 3. replace all of the dismounted stock parts and cowlings in the reverse order from the order in which they were removed 4. Check the operation of the brakes and suspension. Make sure all the bolts are sufficiently tightened. In case the exhaust system touches the cowling or other parts repeat the adjustment of the exhaust system or contact your authorized dealer.! IT IS NORMAL IF WHITE SMOKE COMES OUT OF THE MUFFLER ON FIRST OPERATION.! DO NOT STAND BEHIND THE MUFFLER ON FIRST OPERATION. MAINTENANCE OF THE AKRAPOVIC EXHAUST SYSTEM 1. Do not use aggressive chemical cleaners, because they can damage the sticker. A change in the color of the exhaust system is normal due to the high temperatures. 2. The wearing out of the muffler silencing material depends on the type of the motor and riding style. Contact your dealer/serviceman if visible changes appear on muffler's outer sleeve or the noise level is increased. 3. Periodically check if all the bolts and springs are sufficiently tight. Photos: Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 NAV-017 3

4 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 NAV-017 4

5 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 NAV-017 5

6 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 NAV-017 6

7 M-TTLE2/1 FULL TITANIUM MUFFLER M-TCLE2/1 TITANIUM/CARBON FIBER OUTER SLEEVE MUFFLER P-HF32 HANGING FITTING ASSEMBLY P-34 INNER SLEEVE P-MCTL8 CARBON FIBER CLAMP P-MCCL8 P-FHR6 FLANGE L-H6R6TL LINK PIPE H-H6RT6 HEADER TUBE SET P-ST2A STICKER P-LBSB1 LAMBDA CONNECTOR BOLT C-H6RT6 COLLECTOR SET P-S1 SPRING NAV - 017

8 WARNING: Please note that certain aftermarket exhaust systems may not comply with applicable California laws and regulations, and may therefore be prohibited for use on California highways or roads, or on roads or vehicles otherwise subject to emissions control requirements. Akrapovič exhaust systems for automobiles and motorcycles mounted downstream of the catalytic converter (also known as cat-back systems ) are considered replacement parts in California by the California Air Resources Board (CARB), and do not require an exemption or executive order from CARB to be sold in California. However, California prohibits the use of any aftermarket exhaust system that modifies, removes or replaces original equipment catalysts, unless CARB has issued an Executive Order as to such part or system. Further, Akrapovič parts or exhaust systems used or intended for use on racing vehicles (i.e. a competition vehicle used exclusively for competition on closed-course circuits) do not require an exemption or Executive Order from CARB to be sold in California. However, such parts are prohibited from use on California public highways or roads, even if occasionally used off-road.

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